SUZUKI DR650 MAINTENANCE & MODIFICATIONS (40,000 to 75,000 km MARK)

40,000 - 75,000 km maintenance log for my Suzuki DR650SE (2010).

This entry is going to serve as an extensive maintenance log for my Suzuki DR650 including modifications made before and during the trip. For the report on the first 40,000 km have a look here: http://motoadventurejournal.blogspot.com.ar/2015/08/suzuki-dr650-maintenance-modifications.html

Coating the DR650 in salt, that's good for bikes right?

This entry will cover the 40,000 to 75,000 km mark which I covered end of 2015 until now (May 2016). All of it in South America. The last entry ended like this...

“38000 Km maintenance conducted:

-          New set of chain and sprockets (front and rear, back to standard gearing).

-          Replaced rear wheel and hub bearings (just a precaution).

-          Replaced the front brake line with an original Suzuki line.

-          New spark plugs (just a precaution).

-          New fuel lines and fuel filters (the Safari lines were cracking).

-          Rear rack bent back in place and welded.

-          Carburettor stripped and cleaned (float bowl had gotten stuck twice on the journey).

-          Air filter clean.

-          Lubrication of all cables and moving parts.

-          Valve clearance check (all perfect still).

-          General checks on all working parts.

40000 Km maintenance conducted (prior shipment to South America):

-          New front and rear Heidenau K60 tires

-          Oil & filter change.

-          New front fender (purely for sexiness).

A few things that I will do before shipping if time permits:

-          Rear shock service (re-gas and fresh oil).

-          Re-grease swing-arm and steering head bearings.

-          Cut and weld foot pegs to lower them by 1 inch.”

So the bike was back in mechanical A1 condition. Unfortunately I did not have time to do the last 3 things before shipping. Either way the DR arrived safely in Chile about 8 weeks after departure.

Arrival in Chile, getting back into the swing of things.

Maintenance conducted at 46,000 km (Argentina):

-          Oil change.

-          Air filter clean and re-oil.

And at 47,000 km (Argentina):

-          Welded cracked pannier frame.

-          Fixed GPS contact points (was losing power).

Happy Trail pannier racks, been welded plenty of times... but honestly I think after all those corrugations it would've happened with any brand.

At 49,800 km (Chile) I had my first flat tire with this bike, repaired road side with a replacement tube. And at 50,000 km:

-          New fork seals (they were leaking badly).

-          New rear tire (Heidenau K60 only lasted 10,000 km)

The only flat tire in 75,000 km round the world... couldn't have hoped for much better!

52,000 km (Argentina):

-          Rear brake pads replaced (Kept one of the old ones as it was only half worn).

-          Oil and filter change.

Backyard oil and filter change, basically every couple of weeks.

At 53,000 km (Chile) the rear rack needed more welding. Again hairline fractures had developed from all the corrugations. At 58,000 km (Chile) I changed the oil and cleaned the air filter. The astute observer will notice I stretched all of the last three changes by 1000 km, there was just no opportunity to change it earlier and the riding has been mostly easy highway kilometres.

Welding goggles or glass? Not for this guy!

At the 58,800 km (Peru) mark I had to adjust the chain for the first time since fitting the new one (over 20,000 km ago). I also fitted a new front sprocket.

It wouldn't be a DR post if there wasn't a cheeky dig at a broken down KLR... (just a small short circuit)

59,900 km (Peru): Replaced rear tire (Heidenau K60 this time only lasted 9,900 km and was down to the weave).

I don't know why I wasn't having any luck with Heidenau's... not impressed though.

At 61,000 km (Peru) my starter switch needed cleaning to function before it totally packed it in at 62,000 km (Ecuador). From them on I just manually connected the two wires.

When I replace this next time it's going to be a Chinese rip off for sure.

63,500 km maintenance (Colombia):

-          Oil and filter change.

-          Air filter clean and re-oil.

-          New front brake pads.

At 68,000 km (Ecuador):

-          Oil change.

-          Adjusted chain tension.

-          Thoroughly cleaned the motorcycle, degreased and regreased all external moving parts.

"Major service", looking forward to having my own garage again back home!

In Brazil around 71,000 km:

-          Oil and filter change. Prematurely conducted due to convenience in Brasilia.

-          New rear tire (Pirelli M60 had lasted 11,000 km and had 1mm tread left).

-          Adjusted chain tension.

-          Replaced singular worn brake pad with old one I had kept from 52,000 km replacement in Argentina. Pad on the piston side seems to wear faster.

When the hostel doesn't really have the space...

74,000 km. Chain tension adjusted twice since 71,000 km. Can tell it is nearing the end of its useable life. Get me to Buenos Aires! Well after 76,000 km I did finally arrive in the Capital. Here I cleaned the air filter and prepared a list of things that need to be done once back home. Here it is:

-          Oil change.

-          New starter button.

-          Replace chain and sprockets.

-          Rear shock service (re-gas and fresh oil).

That’s all! But for fun I will likely re-spray some parts where the paint has worn and fit some proper knobby tires for off-road. Overall I am so pleased with this bike for the trip I’ve just done, the best part is being able to ride around the world, drop it a 100 times in the dirt and abuse it daily with relatively few issues. But I am still looking forward to riding a bike with some decent horsepower again, shhh don’t tell the DR.

Amazing memories on this bike, Patagonia!

High up above 4000 m in Argentina!

A few final points I've learnt... the bike's consumption has ranged from 4.5 L/100 km to 6.5 L/100 km. Varying depending on altitude, velocity, etc. She doesn't burn a single drop of oil, ever. Above 3500 m altitude I need to remove the air box side lid (lean it out) otherwise the bike becomes un-rideable. Original engine, gearbox and clutch with zero dramas in that area. I might do another one of these at 100,000 km but since my trip is over for now that might take a little time...

It may cost more than it's worth to send my baby home, but I doubt I'll ever part with her.